Patrick O'Connor, Stevenage, UK
Since 1995 Patrick O'Connor has worked as an independent consultant on engineering management, reliability, quality and safety. He received his engineering training at the Royal Air Force Technical College and served for 16 years in the RAF Engineer Branch, including tours on aircraft maintenance and in the Reliability and Maintainability office of the Ministry of Defence (Air). He was appointed Reliability Manager of British Aerospace Dynamics in 1980 and joined British Rail Research as Reliability Manager in 1993. Mr. O'Connor is the author of Practical Reliability Engineering, published by John Wiley (4th. edition 2002). He is also the author of the chapter on reliability and quality engineering in the Academic Press Encyclopaedia of Physical Science and Technology, and until 1999 was the UK editor of the Wiley journal Quality and Reliability Engineering International. He has written many papers and articles on quality and reliability engineering and management, and he lectures at universities and other venues on these subjects. He is editor of the Wiley book series in quality and reliability engineering.

Andre Kleyner, Delphi Electronics & Safety, USA
Andre Kleyner has over 25 years of engineering, research, consulting, and managerial experience specializing in reliability of electronic and mechanical systems designed to operate in severe environments. He received the doctorate in Mechanical Engineering from University of Maryland, and Master of Business Administration from Ball State University. Dr. Kleyner is a Global Reliability Engineering Leader with Delphi Electronics & Safety, and an adjunct professor at Purdue University. Andre developed and taught many training courses for reliability, quality, and design professionals. He also holds several US and foreign patents and authored professional publications on reliability, quality, and other engineering topics. Andre has is a senior member of American Society for Quality, Certified Reliability and Quality Engineer and Six-sigma black belt. He holds several US and foreign patents and hs authored many papers on the topics of warranty, lifecycle cost, reliability, and statistics. His areas of expertise are: Design for Reliability (DfR); Reliability of Electronic and Mechanical Systems; Product Test and Validation Planning; Physics of Failure; Warranty Management; Reliability Prediction and Warranty Forecasting; Weibull Analysis; Monte Carlo Simulation; Systems Engineering; Dependability analysis, and testing of energy systems for power electronics and electric/hybrid vehicles, and Training and consulting in these areas.

Preface to the First Edition xv

Preface to the Second Edition xvii

Preface to the Third Edition xix

Preface to the Third Edition Revised xxi

Preface to the Fourth Edition xxiii

Preface to the Fifth Edition xxv

Acknowledgements xxvii

1 Introduction to Reliability Engineering 1

1.1 What is Reliability Engineering? 1

1.2 Why Teach Reliability Engineering? 2

1.3 Why Do Engineering Products Fail? 4

1.4 Probabilistic Reliability 6

1.5 Repairable and Non-Repairable Items 7

1.6 The Pattern of Failures with Time (Non-Repairable Items) 8

1.7 The Pattern of Failures with Time (Repairable Items) 9

1.8 The Development of Reliability Engineering 9

1.9 Courses, Conferences and Literature 11

1.10 Organizations Involved in Reliability Work 12

1.11 Reliability as an Effectiveness Parameter 12

1.12 Reliability Programme Activities 13

1.13 Reliability Economics and Management 14

Questions 17

Bibliography 18

2 Reliability Mathematics 19

2.1 Introduction 19

2.2 Variation 19

2.3 Probability Concepts 21

2.4 Rules of Probability 22

2.5 Continuous Variation 28

2.6 Continuous Distribution Functions 33

2.7 Summary of Continuous Statistical Distributions 41

2.8 Variation in Engineering 41

2.9 Conclusions 47

2.10 Discrete Variation 48

2.11 Statistical Confidence 51

2.12 Statistical Hypothesis Testing 53

2.13 Non-Parametric Inferential Methods 57

2.14 Goodness of Fit 59

2.15 Series of Events (Point Processes) 61

2.16 Computer Software for Statistics 64

2.17 Practical Conclusions 64

Questions 66

Bibliography 68

3 Life Data Analysis and Probability Plotting 70

3.1 Introduction 70

3.2 Life Data Classification 71

3.3 Ranking of Data 75

3.4 Weibull Distribution 78

3.5 Computerized Data Analysis and Probability Plotting 85

3.6 Confidence Bounds for Life Data Analysis 89

3.7 Choosing the Best Distribution and Assessing the Results 95

3.8 Conclusions 102

Questions 103

Bibliography 107

4 Monte Carlo Simulation 108

4.1 Introduction 108

4.2 Monte Carlo Simulation Basics 108

4.3 Additional Statistical Distributions 108

4.4 Sampling a Statistical Distribution 110

4.5 Basic Steps for Performing a Monte Carlo Simulation 113

4.6 Monte Carlo Method Summary 115

Questions 118

Bibliography 119

5 Load-Strength Interference 120

5.1 Introduction 120

5.2 Distributed Load and Strength 120

5.3 Analysis of Load-Strength Interference 123

5.4 Effect of Safety Margin and Loading Roughness on Reliability (Multiple Load Applications) 124

5.5 Practical Aspects 131

Questions 132

Bibliography 133

6 Reliability Prediction and Modelling 134

6.1 Introduction 134

6.2 Fundamental Limitations of Reliability Prediction 135

6.3 Standards Based Reliability Prediction 136

6.4 Other Methods for Reliability Predictions 141

6.5 Practical Aspects 143

6.6 Systems Reliability Models 143

6.7 Availability of Repairable Systems 147

6.8 Modular Design 151

6.9 Block Diagram Analysis 152

6.10 Fault Tree Analysis (FTA) 157

6.11 State-Space Analysis (Markov Analysis) 158

6.12 Petri Nets 165

6.13 Reliability Apportionment 169

6.14 Conclusions 170

Questions 170

Bibliography 175

7 Design for Reliability 177

7.1 Introduction 177

7.2 Design for Reliability Process 178

7.3 Identify 179

7.4 Design 183

7.5 Analyse 196

7.6 Verify 197

7.7 Validate 198

7.8 Control 198

7.9 Assessing the DfR Capability of an Organization 201

7.10 Summary 201

Questions 202

Bibliography 203

8 Reliability of Mechanical Components and Systems 205

8.1 Introduction 205

8.2 Mechanical Stress, Strength and Fracture 206

8.3 Fatigue 208

8.4 Creep 214

8.5 Wear 214

8.6 Corrosion 216

8.7 Vibration and Shock 216

8.8 Temperature Effects 218

8.9 Materials 220

8.10 Components 220

8.11 Processes 221

Questions 222

Bibliography 223

9 Electronic Systems Reliability 225

9.1 Introduction 225

9.2 Reliability of Electronic Components 226

9.3 Component Types and Failure Mechanisms 229

9.4 Summary of Device Failure Modes 243

9.5 Circuit and System Aspects 244

9.6 Reliability in Electronic System Design 245

9.7 Parameter Variation and Tolerances 254

9.8 Design for Production, Test and Maintenance 258

Questions 259

Bibliography 260

10 Software Reliability 262

10.1 Introduction 262

10.2 Software in Engineering Systems 263

10.3 Software Errors 265

10.4 Preventing Errors 267

10.5 Software Structure and Modularity 268

10.6 Programming Style 269

10.7 Fault Tolerance 269

10.8 Redundancy/Diversity 270

10.9 Languages 270

10.10 Data Reliability 272

10.11 Software Checking 272

10.12 Software Testing 274

10.13 Error Reporting 275

10.14 Software Reliability Prediction and Measurement 276

10.15 Hardware/Software Interfaces 281

10.16 Conclusions 281

Questions 283

Bibliography 283

11 Design of Experiments and Analysis of Variance 284

11.1 Introduction 284

11.2 Statistical Design of Experiments and Analysis of Variance 284

11.3 Randomizing the Data 296

11.4 Engineering Interpretation of Results 297

11.5 The Taguchi Method 297

11.6 Conclusions 301

Questions 302

Bibliography 305

12 Reliability Testing 306

12.1 Introduction 306

12.2 Planning Reliability Testing 307

12.3 Test Environments 309

12.4 Testing for Reliability and Durability: Accelerated Test 313

12.5 Test Planning 322

12.6 Failure Reporting, Analysis and Corrective Action Systems (FRACAS) 323

Questions 324

Bibliography 325

13 Analysing Reliability Data 327

13.1 Introduction 327

13.2 Pareto Analysis 327

13.3 Accelerated Test Data Analysis 328

13.4 Acceleration Factor 329

13.5 Acceleration Models 330

13.6 Field-Test Relationship 335

13.7 Statistical Analysis of Accelerated Test Data 336

13.8 Reliability Analysis of Repairable Systems 339

13.9 CUSUM Charts 343

13.10 Exploratory Data Analysis and Proportional Hazards Modelling 346

13.11 Field and Warranty Data Analysis 348

Questions 351

Bibliography 355

14 Reliability Demonstration and Growth 357

14.1 Introduction 357

14.2 Reliability Metrics 357

14.3 Test to Success (Success Run Method) 358

14.4 Test to Failure Method 359

14.5 Extended Life Test 360

14.6 Continuous Testing 361

14.7 Degradation Analysis 362

14.8 Combining Results Using Bayesian Statistics 363

14.9 Non-Parametric Methods 365

14.10 Reliability Demonstration Software 366

14.11 Practical Aspects of Reliability Demonstration 366

14.12 Standard Methods for Repairable Equipment 367

14.13 Reliability Growth Monitoring 373

14.14 Making Reliability Grow 382

Questions 383

Bibliography 385

15 Reliability in Manufacture 386

15.1 Introduction 386

15.2 Control of Production Variability 386

15.3 Control of Human Variation 390

15.4 Acceptance Sampling 391

15.5 Improving the Process 395

15.6 Quality Control in Electronics Production 399

15.7 Stress Screening 402

15.8 Production Failure Reporting Analysis and Corrective Action System (FRACAS) 404

15.9 Conclusions 405

Questions 405

Bibliography 406

16 Maintainability, Maintenance and Availability 408

16.1 Introduction 408

16.2 Availability Measures 409

16.3 Maintenance Time Distributions 410

16.4 Preventive Maintenance Strategy 411

16.5 FMECA and FTA in Maintenance Planning 415

16.6 Maintenance Schedules 415

16.7 Technology Aspects 415

16.8 Calibration 417

16.9 Maintainability Prediction 417

16.10 Maintainability Demonstration 418

16.11 Design for Maintainability 418

16.12 Integrated Logistic Support 418

Questions 419

Bibliography 420

17 Reliability Management 421

17.1 Corporate Policy for Reliability 421

17.2 Integrated Reliability Programmes 421

17.3 Reliability and Costs 424

17.4 Safety and Product Liability 428

17.5 Standards for Reliability, Quality and Safety 428

17.6 Specifying Reliability 431

17.7 Contracting for Reliability Achievement 432

17.8 Managing Lower-Level Suppliers 434

17.9 The Reliability Manual 435

17.10 The Project Reliability Plan 436

17.11 Use of External Services 436

17.12 Customer Management of Reliability 437

17.13 Selecting and Training for Reliability 439

17.14 Organization for Reliability 440

17.15 Reliability Capability and Maturity of an Organization 442

17.16 Managing Production Quality 444

17.17 Quality Management Approaches 446

17.18 Choosing the Methods: Strategy and Tactics 447

17.19 Conclusions 448

Questions 449

Bibliography 450

Appendix 1 The Standard Cumulative Normal Distribution Function 451

Appendix 2 ¿2(¿, ¿) Distribution Values...